Automated guided vehicle and method of use

ABSTRACT

A storage system comprises one or more automated guided vehicles, one or more centralized supervisory systems, one or more parts container storage spaces disposed within a defined two dimensional space comprising one or more addressable parts container spaces and parts bins which comprise a part identifier and which are configured to fit at least partially within the parts container storage space. The automated guided vehicles comprise a controllable autonomous parts container base and one or more position sensors operatively in communication with a controller and operative to determine a coordinate location of the automated guided vehicle within a defined two dimensional space in real time without relying on a map stored in the controller.

RELATION TO OTHER APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 15/878,879 filed on Jan. 24, 2018 and claims priority from U.S.Provisional Application 62/449,941 titled “Automated Forklift System”and filed on Jan. 24, 2017.

FIELD OF THE INVENTION

Automated guided vehicles (AGVs) are typically self-powered, self-drivenvehicles used to transport material and other items from one location toanother without any accompanying operator. Traditional AGV systemscomprise a centralized computer system which is in contact with one ormore AGVs deployed in a facility. In certain AGV systems, thiscontroller can be a single, centralized one or dispersed in adecentralized manner.

BACKGROUND

Automated guided vehicles (AGVs) are typically self-powered, self-drivenvehicles used to transport material and other items from one location toanother without any accompanying operator. Traditional AGV systemscomprise a centralized computer system which is in contact with one ormore AGVs deployed in a facility. In certain AGV systems, thiscontroller can be a single, centralized one or dispersed in adecentralized manner.

DRAWINGS

The figures supplied herein illustrate various embodiments of theinvention. Items not expressly illustrated in the drawings are notnecessary for the understanding of the subject matter sought to bepatented by one of ordinary skill in these arts.

FIG. 1 is a schematic diagram of an exemplary system;

FIG. 2 is a view in partial perspective of three exemplary automatedguided vehicles;

FIG. 3A is a block diagram of an exemplary automated guided vehicleillustrating various controls.

FIG. 3B is a block diagram of a further exemplary automated guidedvehicle illustrating various controls

FIG. 4 is a view in partial perspective of a first exemplary automatedguided vehicle;

FIG. 5 is a view in partial perspective of a second exemplary automatedguided vehicle;

FIG. 6 is a view in partial perspective of a third exemplary automatedguided vehicle;

FIG. 7 is a further view in partial perspective of the third exemplaryautomated guided vehicle; and

FIG. 8 is a further view in partial perspective of the third exemplaryautomated guided vehicle.

BRIEF DESCRIPTION OF EXEMPLARY EMBODIMENTS

Referring to FIG. 1, storage system 2 comprises one or more automatedguided vehicles 1, which are as described below; one or more centralizedsupervisory systems 500; one or more parts container storage spaces 510,each parts container storage space 510 comprising one or moreindividually addressable parts container spaces 512 disposed within adefined two dimensional space 3; one or more parts bins 520, each partsbin 520 comprising part identifier 521 which can be an optical,electromagnetic, or similar device, where parts bins 520 are configuredto fit at least partially within addressable parts container spaces 512;and software operatively executable in controller 500. A plurality ofaddressable parts container spaces 512 may stacked, e.g. vertically,within one container storage space 510. Each parts bin 520 can contain aremovable part container 440.

Centralized supervisory system 500 typically comprises a processor and asupervisory system transceiver operatively in communication with theprocessor.

The software operatively executable in controller 500 typicallycomprises a location module adapted to identify a real-time location ofeach controllable autonomous parts container base (illustrated in FIG. 2as 100,200,300 and discussed below) in two dimensional space 3; a motiveassembly module adapted to provide a set of navigation commands to eachcontrollable autonomous parts container base 100,200,300 in twodimensional space 3 in real time; a parts container module adapted toidentify each parts bin 520 using its parts bin identifier 521 and toprovide a set of commands to each part container handler such as 230(FIG. 5) or 330 (FIG. 7) to perform a predetermined function withrespect to the identified parts bin 520. Parts bin identifier 521 may beinternal (e.g., applied on) or internal (e.g. embedded in) to parts bin520.

Referring now to FIG. 2, automated guided vehicle 1 comprisescontrollable autonomous parts container base, illustrated in FIG. 2 asembodiments 100, 200, and 300 which are explained below, one or morepart container storage space receivers 110 (FIG. 4), 210 (FIG. 5), 310(FIG. 6) disposed about predefined portion of controllable autonomousparts container base 100, 200, 300 and operatively in communication withcontroller 340 (FIGS. 3A and 3B), and one or more part containeridentifiers 380 (FIGS. 3A and 3B) operatively in communication withcontroller 340.

In embodiments, referring now to FIGS. 3A and 3B, controllableautonomous parts container base 100, 200, 300 comprises housing 330,controller 340 disposed at least partially within housing 330, one ormore position sensors 350 operatively in communication with controller340, each position sensor 350 operative to determine a coordinatelocation of housing 330 within defined two dimensional space 3 (FIG. 1)in real time without relying on a map stored in controller 340, one ormore transceivers 360 operatively in communication with controller 340,and motive assembly 370 operatively in communication with controller340, where motive assembly 340 is operative to move controllableautonomous parts container base 100, 200, 300 autonomously within thedefined two dimensional space 3 under directives from controller 340without the need for a map stored in controller 340.

Controller 340 may comprise one or more processors able to allowsoftware executing in controller 340 to have controller 340 be operativeto command various functions required by automated guided vehicles 1such as via transceiver 360 and communicate with other entities, e.g.centralized supervisory system 500 via transceiver 501, automated guidedvehicles 1, other systems such as inventory systems, and the like, or acombination thereof.

Position sensors 350 operate by sensing a current position of automatedguided vehicle 1 along a grid deployed in two dimensional space 3.

Transceivers 360 are operatively in communication, typicallybidirectional, between automated guided vehicles 1 and centralizedsupervisory system 500 such as via transceiver 501. They may also be incontact with one or more other automated guided vehicles 1 or the like.

Motive assembly 370 typically comprises an omnidirectional motiveassembly and typically comprises two or more sets of wheels 372 or thelike. Each motive assembly 370 is adapted to provide or respond to a setof navigation commands to its controllable autonomous parts containerbase 100,200,300 navigate that controllable autonomous parts containerbase 100,200,300 to an addressable parts container space 510 using anaddress for that addressable parts container space 510.

Part container identifiers 380 operatively in communication withcontroller 340 and operative to interrogate parts container identifier421 to identify a parts container by its parts container identifier 421,e.g. bar codes (which can be optical), embedded chips, or the like, or acombination thereof.

Referring to FIG. 4, in the embodiment illustrated as controllableautonomous parts container base 100, controllable autonomous partscontainer base 100 comprises housing 330 (FIG. 3A).

Referring now to FIG. 5, as illustrated in other embodiments, e.g.controllable autonomous parts container base 200, controllableautonomous parts container base 200 may comprise housing 330 (FIG. 3A)as part of its base 203 or as part of an end piece such as 201 or 202.In this embodiment, part container storage space receiver 210 comprisesfirst end 211 and second end 212 displaced from first end 211 along ahorizontal axis of controllable autonomous parts container base 200.First end 211 and second end 212 define parts container 220. Selectivelymovable part container handler 230 may be present and disposed at leastpartially within parts container 220 where part container handler 230may further be operatively in communication with controller 340 (FIG.3A) and operative to move containers such as selectively removablepallet 240 along a vertical axis with respect to parts container 220 ofcontrollable autonomous parts container base 200. Part container storagespace receiver 210 is typically disposed about upper surface 205 ofcontrollable autonomous parts container base 200 and may be furtherdisposed proximate first end portion 202 of controllable autonomousparts container base 200 and/or intermediate first end 211 and secondend 212.

In other embodiments, referring now to FIG. 6, controllable autonomousparts container base 300 may comprise housing 330 (FIG. 3B) as part ofits base 303 or as part of an end piece such as 301 or 302. First end301 and second end 302 of controllable autonomous parts container base300 define part container storage space receiver 310 for selectivelymovable part container handler 400 disposed at least partially withinpart container storage space receiver 310 intermediate first end portion301 and second end portion 302 of controllable autonomous partscontainer base 300. Part container storage space receiver 310 istypically disposed about an upper surface 305 (FIG. 3B) of controllableautonomous parts container base 300 and may be further disposedproximate first end portion 302 of controllable autonomous partscontainer base 300 and/or intermediate first end 301 and second end 302.

Part container handler 400 is typically operatively in communicationwith controller 340 (FIG. 3B) and operative to move itself and/or one ormore part containers 440 which are selectively and removably disposedwithin a plurality of part container storage space receiver spaces 412.Parts container 440 may comprise parts container identifier 421. Inthese embodiments, part container handler 400 comprises part containerhandler 330 which is movable in at least two dimensions and commandableto select a specific part container 440 accepted into a specific partcontainer storage space receiver space 412 of the plurality of partcontainer storage space receiver spaces 412 and/or to allow receipt of aspecific part container 440 into a specific part container storage spacereceiver space 412 of the plurality of part container storage spacereceiver spaces 412.

In the operation of exemplary embodiments, referring again to FIG. 1,storage system 2 may be used to allow one or more autonomous guidedvehicles 1 to go out into two dimensional space 3, such as a warehousefloor or other item storage area, and retrieve one or more partscontainers 440, or one or more parts from one or more parts containers440, or other similar objects, and bring the retrieved containers and/orparts to a requesting entity such as a user at a work station. As usedherein a user may be a human user or, e.g., a robot such as on anassembly line.

Although an exemplary two dimensional space 3 is a warehouse floor, suchis not a limitation. By way of example and not limitation, twodimensional space 3 may comprise an office environment where autonomousguided vehicle 1 might deliver office mail or office supplies; a lightindustrial space, e.g. delivering parts containers 440 to variousworkstations; an industrial factory setting where autonomous guidedvehicle 1 is reloading parts hoppers from a warehouse or deliveringon-time parts to assembly line workers and/or robots (e.g. an autoassembly line); a standard roadway where autonomous guided vehicle 1 maybe used to deliver mail or packages/parcels; a cargo transfer points tomove packages from one transport to another in a cargo transit station(e.g. a post office, cargo terminal, or other package transfer station);a retail establishments where autonomous guided vehicle 1 may be used tostock and/or restock goods by transferring stock from a store's backwarehouse to retail shelves or to re-shelve books in a library; or thelike; or a combination thereof.

One or more such autonomous guided vehicles 1 may be part of storagesystem 2, and, if a plurality is present, the plurality of autonomousguided vehicles 1 may comprise a mix of autonomous guided vehicles 1which further comprise a mix of controllable autonomous parts containerbases 100, 200, and 300. In embodiments, autonomous guided vehicles 1can retrieve multiple objects in one trip into two dimensional space 3.

As is described below, parts may be obtained from one or more parts bins520 present in parts container storage space 510 of storage system 2,described above, by using an analytic software module operative incentralized supervisory system 500 to identify a vehicle opportunity toperform a required task, e.g. an optimal or other acceptable autonomousguided vehicle 1 to retrieve an item or return an item or perform apredetermined set of inventory functions or the like, and optimizeselection of an autonomous guided vehicle 1 for the required task.Selection criteria can include capacity of such autonomous guidedvehicles 1, current location of autonomous guided vehicles 1, currenttasking for autonomous guided vehicles 1, and the like, or a combinationthereof.

A vehicle selection optimization module is then used to notify theidentified controllable autonomous guided vehicle 1 of its selection forthe required task and the vehicle positioning module used to provide theidentified, selected controllable autonomous guided vehicle 1 with anaddress for the appropriate addressable parts container storage space510 within two dimensional space 3, the address defining a destinationlocation within two dimensional space 3, and with a set of commandsrelated to a specific parts bin 520 which comprises part bin identifier521 associated with the required task.

The identified controllable autonomous guided vehicle 1 is allowed tothen navigate, typically autonomously, to the addressable partscontainer space 512 comprising the address using motive assembly 370 ofthe identified controllable autonomous guided vehicle 1. Once it hasarrived at the address, the identified controllable autonomous guidedvehicle 1 uses its selectively movable part container handler 230,330 toperform a specifically commanded operation with respect to the specificparts bin 520 which comprises part bin identifier 521 associated withthe required task, typically automatically. This specifically commandedoperation may comprise commanding selectively movable part containerhandler 230,330 to move to a position proximate parts bin 520 and verifythat parts container 440 is the desired parts container 440 using, e.g.,part container identifiers 380 and parts container 421. If verified,selectively movable part container handler 230,330 obtains partscontainer 440 from parts bin 520, and positions parts container 440 inpart container storage space receiver space 412 or returns positionsparts container 440 into position parts bin 520.

In its embodiments, using the vehicle positioning module to provide theidentified controllable autonomous guided vehicle 1 with an address foran addressable parts container space 520 further comprises providing theidentified controllable autonomous guided vehicle 1 with a plurality ofaddresses, each address being for a specific addressable parts containerspace 512 within two dimensional space 3 and providing the identifiedcontrollable autonomous guided vehicle 1 with a set of commands relatedto a plurality of specific parts containers 440, each specific partscontainer 440 located at a predetermined address of the plurality ofaddresses. The identified controllable autonomous guided vehicle 1navigates to each addressable parts container space 512 of the pluralityof addresses using motive assembly 370 of the identified controllableautonomous guided vehicle 1.

In certain embodiments, the identified controllable autonomous guidedvehicle 1 is also provided one or more destination locations, e.g.return locations, within two dimensional space 3 that are associatedwith a predetermined set of specific parts containers of the pluralityof specific parts containers 440. If a return or destination address hasalso been identified, e.g. by centralized supervisory system 500, theidentified autonomous guided vehicle 1 is then allowed to autonomouslynavigate to one or more destination locations once a set of commands arecompleted, e.g. part containers 440 have been retrieved from and/orreturned to parts bins 520.

In its embodiments, software executing in controller 340 (FIGS. 3A and3B) typically operates independently of the storage system's safetyfunctions, thereby maintaining the failsafe nature of storage system 2.Further, in embodiments, software executing in centralized supervisorysystem 500 oversees and controls the health and well-being of allautomated guided vehicles 1 in storage system 2. By way of example andnot limitation, monitoring may include taking an automated guidedvehicle 1 out of normal operation and placing it into maintenance modeif a fault or other health and well-being issue is detected.

In embodiments, software operatively executable in centralizedsupervisory system 500 further comprises a timer module which may beused to perform a set of steps at a predetermined set of times.

By way of example and not limitation, using storage system 2 asdescribed above, a user may want to build something at a workstation andmay need one or more parts from multiple places in a warehouse toaccomplish this task. The user identifies the needed parts andoptionally identifies their respective parts bins. Alternatively,storage system 2 may identify the parts bins associated with therequested parts. Once identified and requests, storage system 2instructs an identified, selected autonomous guided vehicle 1 to go outinto warehouse floor 3, gather all of the requested parts, and bringsthe gathered parts to the user at the requested work station. As will beunderstood by a person of ordinary skill in automated parts retrievalsystems, that which is gathered can be individual parts, parts bins 520,or the like, or a combination thereof.

As further described above, the identified, selected autonomous guidedvehicle 1 or another autonomous guided vehicle 1 may be furtherprogrammed to return the individual parts, parts bins 520, or the like,or a combination thereof to warehouse floor 3 when the use is done withparts from retrieved parts bins 520.

In addition, autonomous guided vehicle 1 can be further programmed tobring parts throughout a construction process, e.g. it might beprogrammed in such a manner that it knows that the user will requireparts from various bins after a defined time, e.g. 1 hour and 20 minutesafter it has delivered parts in an earlier delivery. Using similarmethodology, storage system 2 may be used to bring multiple part loadsto multiple workstations throughout the day as assembly of variouscomponents goes on.

In certain embodiments, storage system 2 may comprise one or moreautonomous guided vehicles 1 which can interface with warehouseinventory systems to assist in part tracking, i.e. what parts have beenused, how many, and where a bin currently is located (if off at someworkstation). By way of example and not limitation, autonomous guidedvehicle 1 can be fitted with terminals or other interfaces by whichaccess to an inventory control system may be obtained, e.g. throughwhich users can interface with to update parts status, request parts,and the like.

The foregoing disclosure and description of the inventions areillustrative and explanatory. Various changes in the size, shape, andmaterials, as well as in the details of the illustrative constructionand/or an illustrative method may be made without departing from thespirit of the invention.

The invention claimed is:
 1. A method of obtaining a parts containerfrom an addressable parts container storage space using a storage systemcomprising an automated guided vehicle, comprising: a. using an analyticsoftware module operative in a centralized system supervisor to identifya vehicle opportunity to perform a required task and to optimizeselection of an autonomous guided vehicle for the required task, theautonomous guided vehicle comprising: i. a controllable autonomous partscontainer base, comprising:
 1. a housing;
 2. a controller disposed atleast partially within the housing;
 3. a position sensor operatively incommunication with the controller, the position sensor operative todetermine a coordinate location of the housing within a definedtwo-dimensional space in real time without relying on a map stored inthe controller;
 4. a transceiver operatively in communication with thecontroller; and
 5. a motive assembly operatively in communication withthe controller, the motive assembly operative to move the controllableautonomous parts container base autonomously within the definedtwo-dimensional space under directives from the controller without theneed for a map stored in the controller; and ii. a part containerstorage space receiver disposed about predefined portion of thecontrollable autonomous parts container base, the part container storagespace receiver operatively in communication with the controller andconfigured to selectively and removably accept a parts containertherein; b. using a vehicle selection optimization module operative inthe centralized system supervisor to notify the identified controllableautonomous guided vehicle of its selection for the task; c. using avehicle positioning module to provide the identified controllableautonomous guided vehicle with an address of an individually addressableparts container storage space within a two: dimensional space and with aset of commands related to the required task and related to a specificseparately individually addressable parts container storage space, theseparately individually addressable parts container storage spacecomprising a separately individually addressable parts container spaceadapted to receive a parts bin comprising a separately individuallyaddressable part container identifier; d. providing the identifiedcontrollable autonomous guided vehicle with a destination locationwithin the two-dimensional space; e. allowing software executing in thecontroller to allow the identified controllable autonomous guidedvehicle to navigate to the specific separately individually addressableparts container storage space within the two-dimensional spacecomprising the address using the motive assembly of the identifiedcontrollable autonomous guided vehicle; f. allowing software executingin the controller to allow the identified controllable autonomous guidedvehicle to use its selectively movable part container handler to performa specifically commanded operation on a parts bin disposed within theidentified addressable parts container space which comprises the partsbin comprising the part container identifier; and g. allowing softwareexecuting in the controller to cause the identified controllableautonomous guided vehicle to navigate to the destination location withina two-dimensional space in real time without relying on a map stored inthe controller.
 2. The method of obtaining a parts container from aparts container storage space using the storage system comprising anautomated guided vehicle of claim 1, further comprising executingsoftware in the controller independently of the storage system's safetyfunctions, thereby maintaining a failsafe nature of the storage system.3. The method of obtaining a parts container from a parts containerstorage space using the storage system comprising an automated guidedvehicle of claim 1, further comprising executing software in thecontroller to oversee and control health and well-being of all automatedguided vehicles in the storage system.
 4. The method of obtaining aparts container from a parts container storage space using the storagesystem comprising an automated guided vehicle of claim 1, furthercomprising taking an automated guided vehicle out of normal operationand placing the automated guided vehicle into maintenance mode.
 5. Themethod of obtaining a parts container from a parts container storagespace using the storage system comprising an automated guided vehicle ofclaim 1, wherein the autonomous guided vehicle comprises a plurality ofautonomous guided vehicles and the optimized selection is of anautonomous guided vehicle of the plurality of autonomous guidedvehicles.
 6. The method of obtaining a parts container from a partscontainer storage space using the storage system comprising an automatedguided vehicle of claim 1, wherein the set of commands related to therequired task and related to the specific separately individuallyaddressable parts container storage space comprises commanding theselectively movable part container handler to move to a positionproximate the separately individually addressable parts container spaceobtain the parts bin disposed within the separately individuallyaddressable parts container space, and position the obtained parts binin the parts container storage space receiver.
 7. The method ofobtaining a parts container from a parts container storage space usingthe storage system comprising an automated guided vehicle of claim 1,wherein: a. using the vehicle positioning module to provide theidentified controllable autonomous guided vehicle with the address foran individually addressable parts container storage space within thetwo-dimensional space and with the set of commands related to therequired task and related to the specific separately individuallyaddressable storage space further comprises: i. providing the identifiedcontrollable autonomous guided vehicle with a plurality of addresses,each address being for a specific addressable parts container storagespace within the two-dimensional space; and ii. providing the identifiedcontrollable autonomous guided vehicle with a set of commands related toa plurality of specific parts bins, each specific parts bins located ata predetermined address of the plurality of addresses; and b. allowingthe identified controllable autonomous guided vehicle to navigate to anaddressable parts container storage space comprising the address usingthe motive assembly of the identified controllable autonomous guidedvehicle further comprises allowing the identified controllableautonomous guided vehicle to navigate to each addressable partscontainer space of the plurality of addresses.
 8. The method ofobtaining a parts container from a parts container storage space usingthe storage system comprising an automated guided vehicle of claim 1,wherein: a. providing the identified controllable autonomous guidedvehicle with a destination location within a two-dimensional spacefurther comprises providing the identified controllable autonomousguided vehicle with a set of destination locations; and b. allowing theidentified controllable autonomous guided vehicle to navigate to thedestination location within a two-dimensional space further comprisesallowing the identified controllable autonomous guided vehicle tonavigate to a specific destination location of the set of destinationlocations, each destination location of the set of destination locationsbeing associated with a predetermined set of specific parts containersof the plurality of specific parts containers.
 9. The method ofobtaining a parts container from a parts container storage space usingthe storage system comprising an automated guided vehicle of claim 1,wherein the software operatively executable in the controller furthercomprises a timer module, the method further comprising using the timermodule to perform a set of steps at a predetermined set of times. 10.The method of obtaining a parts container from a parts container storagespace using the storage system comprising an automated guided vehicle ofclaim 1, further comprising using the identified controllable autonomousguided vehicle to perform a predetermined set of inventory functions.11. The method of obtaining a parts container from a parts containerstorage space using the storage system comprising an automated guidedvehicle of claim 1, wherein: a. the automated guided vehicle furthercomprises a position sensor operatively in communication with thecontroller, the position sensor operative to determine a coordinatelocation of the housing within the two-dimensional space in real timewithout relying on a map stored in the controller; and b. allowingsoftware executing in the controller to allow the identifiedcontrollable autonomous guided vehicle to navigate to the specificseparately individually addressable parts container storage space withinthe two-dimensional space further comprises navigating to the specificseparately individually addressable parts container storage space withinthe two-dimensional space in real time without relying on a map storedin the controller.